Radiator Grille Chrome Frame Assembly With Guided Stamping
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Solution Overview
Problem
Manual joining of motor vehicle components, such as radiator grilles with chrome frames or strips, is labor-intensive and prone to errors and quality loss, especially when trying to align components with large manufacturing tolerances.
Innovation Solution
An automated assembly system with a horizontally aligned component holder and a vertically lowering stamping device, assisted by pneumatically or hydraulically actuated fixing elements and a camera system for precise alignment and force measurement to prevent damage, allows for the secure latching or pressing of components while minimizing mechanical stress on sensitive coatings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual joining operations are used to attach chrome frames or strips to radiator grilles, then flexibility in handling different component variants is maintained, but assembly effort increases and quality consistency deteriorates
Solution Approach 1:
The assembly system is divided into modular components: a reusable component holder that can accommodate different radiator grille variants, and interchangeable punching devices for different chrome frame/strip configurations. This segmentation allows the system to handle multiple variants efficiently without requiring complete reconfiguration.
Solution Approach 2:
The system uses automated punching devices that perform the joining operations without manual intervention. The component holder automatically positions components, and the punching device executes precise joining actions, eliminating the need for manual alignment and attachment operations.
2Ease of operation
If manual joining operations are used to attach chrome frames or strips to radiator grilles, then operator judgment can be applied, but error rate increases and quality consistency deteriorates
Solution Approach 1:
The manual mechanical operations of alignment and joining are replaced with an automated mechanical system. The component holder provides precise positioning, and the punching device delivers consistent joining forces, eliminating variability introduced by manual operations while maintaining the mechanical precision required for quality assembly.
Solution Approach 2:
The system transforms the joining process from a manual skill-based operation to a controlled parameter-based process. The punching device applies predetermined forces at specific locations, and the component holder maintains fixed positioning parameters, ensuring consistent quality outcomes regardless of operator variation.
3Strength
If punching device applies concentrated force to join components, then joining effectiveness is achieved, but risk of damaging sensitive chrome coatings increases
Solution Approach 1:
The punching device applies force not only vertically downward but also with horizontal guiding components. The angled tooth contours provide lateral support and distribution of forces, preventing concentrated stress points that could damage the chrome coatings while maintaining effective joining.
Solution Approach 2:
The angled tooth contours act as intermediary elements between the punching device and the chrome-coated components. These contours distribute the applied force across larger surface areas and provide gradual engagement, preventing direct concentrated impact that could damage the sensitive chrome coatings.
4Manufacturing precision
If components are precisely aligned during manual assembly, then joining accuracy is improved, but assembly time increases
Solution Approach 1:
The component holder pre-positions the radiator grille and chrome frames or strips in the correct alignment before the punching operation begins. This preliminary positioning eliminates the need for time-consuming manual alignment adjustments during the actual joining process, achieving both precision and efficiency.
Solution Approach 2:
The component holder creates a precise geometric copy or template of the desired final assembly configuration. By pre-establishing this template positioning, the system ensures that components are automatically aligned correctly without requiring manual measurement or adjustment, significantly reducing assembly time while maintaining high precision.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The automated system reduces assembly effort and errors, ensures precise alignment and secure joining of components, and protects sensitive coatings by distributing force over a larger surface area, thereby improving efficiency and quality while preventing damage from excessive pressure.
Implementation Method 1
a punching device on the system is moved towards the complete assembly, in particular lowered vertically, such that, in an end position of the punching device, it is subjected to a pressing force that causes the components to lock or press together
Implementation Method 2
the complete assembly is supported against the pressing force by the angled tooth contours of the component fixture at each locking point
Implementation Method 3
the entire component is secured with external force using fixing elements on the component holder side
Data Source
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AI summary
The invention relates to a method, and to an assembly installation (1) for performing said method, for automatically joining components (21, 22, 23), in particular a motor-vehicle radiator grille (21) to a chrome frame (22) and/or a chrome frame to a chrome strip (23), in an assembly installation (1), wherein in a first step a second component (22) is positioned on a first component (21) or a third component (23) is positioned on the second component in order to form a complete component (20), wherein in a second step the complete component (20) is inserted into a component holder (2) of the assembly installation (1), which component holder is preferably oriented substantially horizontally, and wherein in a third step an installation-side stamping device (3) is guided, in particular lowered vertically, in the direction of the complete component (20) in such a way that a pressing force (F) that causes a locking or pressing together of the components (21, 22, 23) is applied to the complete component in an end position of the stamping device (3).